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Battery Junction Box (BJB)



Battery Junction Box (BJB) - 3.2L

Removal
1. Remove the bumper armature.
2. Remove the air cleaner housing.
3. Remove the secondary bulkhead center panel.
4. Remove the brake booster.
5. Remove the ABS module.
6. Remove both headlamps.
7. Remove the engine upper support insulator.
8. Remove the glove compartment lid.

NOTE: RHD illustration shown, LHD is similar.

9. Remove both front fender splash shields.

















19. Release the harness and withdraw into engine bay area.
20. Release the harness cover and withdraw harness into engine bay area.





25. Repeat for both sides.

34. Unclip the windscreen heater electrical connector from the plenum side extension panel and remove the panel.

36. NOTE: LHD illustration shown, RHD is similar.

37. Release the engine compartment harness from clip securing it to the vehicle bulkhead.

38. NOTE: RHD illustration shown, LHD is similar.

41. NOTE: RHD illustration shown, LHD is similar.

NOTE: RHD illustration shown, LHD is similar.

42. RH side front: Release the ABS sensor lead and disconnect the electrical connector.

NOTE: RH illustration shown, LH is similar

43. Release the LH side repeater from the vehicle body and disconnect the electrical connector.





44. NOTE: RHD illustration shown, LHD is similar.

NOTE: RHD illustration shown, LHD is similar.

45. Unclip the harness tray from the vehicle bulkhead and route the RHS of the harness around the brake pipes into the LHS of the engine bay.

46. NOTE: RHD illustration shown, LHD is similar.

47. NOTE: RHD illustration shown, LHD is similar.





48. NOTE: RHD illustration shown, LHD is similar.

49. NOTE: RHD illustration shown, LHD is similar.

50. NOTE: LHD illustration shown, RHD is similar.

51. NOTE: RHD illustration shown, LHD is similar.

NOTE: RHD illustration shown, LHD is similar.

52. With assistance, release the harness.

NOTE: With assistance remove the component.

53. Remove the engine compartment harness.

Installation
1. Place harness to vehicle plenum, feed connectors into inside of vehicle and install grommet. Use assistance inside vehicle to pull connectors through.
2. Secure harness tray clips and secure rubber grommet to vehicle body.
3. Install and secure fusebox to body.

Torque: 10 Nm

4. Install the engine mounting plate.

Torque:
M8.24 Nm
M12.80 Nm

5. Secure the engine harness to the fusebox.
6. Connect the two electrical connectors to the BJB.
7. Install and secure the battery lead to the fusebox and install the small battery lead cover.

Torque: 10 Nm

8. Secure the 3 earth points and secure the harness clips to the vehicle body.

Torque: 10 Nm

9. Secure the battery lead to the battery terminal clamp.

Torque: 25 Nm

10. Install the fuse box cover.
11. Install the harness cover to the suspension turret.
12. Feed harness under the air cleaner duct and secure the duct to the grommet.
13. Secure headlamp and bumper harness clips.
14. Connect the height sensor electrical connector and secure the harness with the clips.
15. Install headlamp mounting plate.

Torque: 10 Nm

16. Connect the side repeater electrical connector.
17. Connect the heated washer jet electrical connection and secure the harness to the vehicle body.
18. Connect the ABS sensor and secure the harness to the vehicle body.
19. Secure the washer pipe to the harness and secure the harness to the body.
20. Connect the crash sensor electrical connectors.
21. Connect the the bonnet lock electrical connector
22. Secure the harness to the body and then secure the bonnet release cable to the harness.
23. Secure the washer pipe to the washer bottle.
24. Install the washer bottle and connect the electrical connections.

Torque: 10 Nm

25. Secure the 3 ground cables to the vehicle body.

Torque: 10 Nm

26. Secure the harness to the vehicle body.
27. Connect the coolant level sensor electrical connector.
28. Install the RH secondary bulkhead mounting bracket.

Torque: 10 Nm

29. Install the inner plenum plate and secure the electrical connector to the plate.
30. Connect the heated screen RH electrical connector.
31. Connect the BBUS electrical connector.
32. Connect the A/C pressure switch electrical connector.
33. Secure the engine compartment harness to the vehicle bulkhead.
34. Secure the harness tray to the LHS of the vehicle bulkhead.
35. Connect the LH heated screen electrical connector and secure the harness to the vehicle body.
36. Feed the harness into the LH wheel arch and secure the grommet.
37. Install the ABS modulator bracket.

Torque: 25 Nm

38. Install the LH side repeater lamp and secure the clips to the vehicle body.
39. Connect the rear washer pipe.
40. Connect the ABS sensor electrical connector and secure the harness to the vehicle body.
41. Connect the two electrical connectors to the CJB.
42. Connect the main engine compartment harness to the instrument panel harness and close the cover.
43. Connect the main engine compartment harness to the headlamp levelling ECU.
44. Connect the 3 floor harness electrical connections.
45. Install the fuse cover and refit the sound deadening sheet.
46. Install the LH fender splash shield.

Torque: 6 Nm

47. Install the glove compartment lid.
48. Install the engine upper support insulator.
49. Install both headlamps.
50. Install the ABS module.
51. Install the brake booster.
52. Install the secondary bulkhead center panel.
53. Install the air cleaner housing.
54. Install the bumper armature.
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